Mil-COTS

Products for the Military and Aerospace Industry

Military “Off-The-Shelf” dc-dc converters

Advancing the Power Curve®

Made in USA

“Off-the-shelf” DC-DC converters for military/avionics cost sensitive applications The MilQor series of Mil-COTS DC-DC converters brings SynQor’s field proven high-efficiency synchronous rectifier technology to the Military/Avionics industry. These “off-the-shelf” converters are compatible with the industry standard format, operate at a fixed frequency, and follow conservative component derating guidelines. MilQor products are designed and manufactured to comply with a wide range of military standards.

OPERATIONAL

• High efficiency, up to 95% at full rated load current • Operating input voltage range: 9-75V, 155-425V • Fixed frequency switching provides predictable EMI • No minimum load requirement • Rugged design for harsh environments • Full Feature optional on some models

MECHANICAL

• Industry standard pin-out configurations • Flanged baseplate available • Industry standard footprints:Full Brick: 2.48" x 4.69"Half Brick: 2.39" x 2.49"Quarter Brick: 1.54" x 2.39"Sixteenth Brick: 1.04" x 1.44"

CONTROL

• On/Off control referenced to input side • Remote sense for the output voltage • Trimable output voltages • See data sheets for more information.

PROTECTION

• Input under-voltage lockout • Output current limit and short circuit protection • Active back bias limit • Output over-voltage protection • Thermal shutdown

IN-LINE MANUFACTURING PROCESS

• AS9100 and ISO 9001:2008 certified facility • Full component traceability • Environmental screening options available

SAFETY

• IEC 60950-1 2nd Edition

Mil-COTS 28, 28E, 28V, 28VE and 48 • Basic Insulation • 2250V, 30MΩ input-to-output isolation

Mil-COTS 270, 270H, 270N • Reinforced Insulation • 4250V, 100MΩ input-to-output isolation

PRODUCT FEATURES

Visit our website for more information

Mil-COTS

95% Efficiency

“Off-the-shelf” DC-DC Converters for Military/Aerospace Cost Sensitive Applications The MilQor series of Mil-COTS DC-DC converters brings SynQor’s field proven high-efficiency synchronous rectifier technology to the Military/Aerospace industry. These “off-the-shelf” converters are compatible with the industry standard format, operate at a fixed frequency, and follow conservative component derating guidelines. MilQor products are designed and manufactured to comply with a wide range of military standards.

* Converters may be operated continuously at the highest transient input voltage, but some component electrical and thermal stresses would be beyond MIL-HDBK-1547A guidelines.

MCOTS-28 Brick Size 1.2V 1.5V 1.8V 2.5V 3.3V 5V 7V 7.5V 12V 15V 24V 28V 40V 48V 50V

16-40Vin Cont.50Vin 1s Trans.*Absolute Max Vin = 60V

1/2Zeta

60A300W

42A504W

34A510W

21A504W

18A504W

12.5A500W

10A500W

1/2Peta

60A108W

50A165W

40A200W

27A202W

16A192W

13A195W

8.33A200W

7A196W

5A200W

4A192W

1/4EXA

40A200W

25A300W

20A300W

11A300W

6A300W

1/4 40A48W

40A60W

40A72W

40A100W

30A99W

24A120W

17A119W

10A120W

8A120W

5A120W

4A112W

3A120W

2.5A120W

1/16 25A30W

25A38W

25A45W

20A50W

15A50W

10A50W

7A49W

4A48W

MCOTS-28E Brick Size 1.5V 1.8V 2.5V 3.3V 5V 7V 7.5V 12V 15V 24V 28V 30V 40V 48V 50V

16-70Vin Cont.100Vin 1s Trans.*Absolute Max Vin = 100V

1/2Zeta

60A300W

33A396W

26A390W

16A384W

14A392W

10A400W

8A400W

1/2Peta

60A108W

50A165W

36A180W

24A180W

15A180W

12A180W

7.5A180W

6.5A182W

4.5A180W

3.7A178W

1/4 30A99W

24A120W

10A120W

8A120W

4.3A120W

2.5A120W

MCOTS-48 Brick Size 1.2V 1.5V 1.8V 2.5V 3.3V 5V 7V 12V 15V 24V 28V 30V 40V 48V 50V

34-75Vin Cont.100Vin 1s Trans.*Absolute Max Vin = 100V

1/2Zeta

60A300W

50A600W

40A600W

25A600W

21.5A602W

15A600W

12A600W

1/2Peta

60A72W

60A90W

60A108W

60A150W

60A198W

46A230W

35A245W

21A252W

17A255W

10.5A252W

9A252W

6.3A252W

5.2A250W

1/4 40A48W

40A60W

40A72W

40A100W

30A99W

25A125W

20A140W

12A144W

10A150W

6A144W

4A112W

5A140W

3A120W

3A144W

1/16 25A30W

25A38W

25A45W

20A50W

15A50W

10A50W

7A49W

4A48W

3A45W

MCOTS-28V Brick Size 1.5V 1.8V 2.5V 3.3V 5V 7V 7.5V 12V 15V 24V 28V 30V 40V 48V 50V

9-40Vin Cont.55Vin 1s Trans.*Absolute Max Vin = 60V

1/2Zeta

50A250W

21A252W

17A255W

10A240W

9A252W

6A240W

5A250W

1/2Peta

60A108W

50A165W

36A180W

24A180W

15A180W

12A180W

7.5A180W

6.5A182W

4.5A180W

3.7A178W

1/4 35A63W

25A83W

17A85W

12A84W

7A84W

5.5A83W

3.5A84W

2.8A78W

1.8A86W

MCOTS-28VE Brick Size 1.5V 1.8V 2.5V 3.3V 5V 7V 7.5V 12V 15V 24V 28V 30V 40V 48V 50V

9-70Vin Cont.100Vin 1s Trans.*Absolute Max Vin = 100V

1/2Zeta

50A250W

21A252W

17A255W

10A240W

9A252W

6A240W

5A250W

1/2Peta

55A99W

45A149W

32A160W

22A165W

13A156W

11A165W

6.7A161W

5.8A162W

4A160W

3.4A163W

1/4 25A83W

17A85W

12A84W

7A84W

5.5A83W

3.5A84W

2.8A78W

1.8A86W

MCOTS-270 Brick Size 3.3V 5V 12V 15V 24V 28V 48V

155-425Vin Cont.475Vin 1s Trans.*Absolute Max Vin = 600V

Full 80A400W

50A600W

40A600W

25A600W

21.4A600W

12.5A600W

1/2 60A198W

50A250W

25A300W

20A300W

12.5A300W

10.7A300W

6.2A300W

1/4 30A99W

30A150W

13A156W

10A150W

6.25A150W

5.35A150W

3.12A150W

MCOTS-270H Brick Size 5V 28V 36V

240-425Vin Cont.475Vin 1s Trans.*Absolute Max Vin = 600V

Full 10A500W

28.6A800W

22.2A800W

MCOTS-270N Brick Size 8V 10V 28V

240-280Vin Cont.200-350Vin 1s Trans.*Absolute Max Vin = 600V

Half 50A400W

40A400W

14.5A400W

PRODUCT FEATURES

OPERATIONAL

• High efficiency, up to 95% at full rated load current • Delivers 32A full power with minimal derating - no heatsink required

• Operating input voltage range: 230-400 & 440-700V • Fixed frequency switching provides predictable EMI • No minimum load requirement

MECHANICAL

• Industry standard half-brick pin-out configurationHalf Brick: 2.39” x 2.49”

• Total Baseplate weight: 2.7 oz. (78 g)

CONTROL

• On/Off control referenced to input side Inherent current share (by droop method) for high current and parallel applications

PROTECTION

• Input under-voltage and over voltage lockout protects against abnormal input voltages

• Output current limit and short circuit protection (auto recovery)

• Thermal shutdown

IN-LINE MANUFACTURING PROCESS

• AS9100 and ISO 9001:2008 certified facility • Full component traceability • Environmental screening options available

SAFETY

• IEC 60950-1 2nd Edition

Mil-COTS Isolated DC-DC Bus ConvertersModel Number Package

SizeInput

VoltageInput

TransientOutput Voltage

Output Current Max Output Power Efficiency

MCOTS-B-270-31 1/2 Brick 230-400Vin 155-450Vtrans 31Vout 32A 1000W 95%

MCOTS-B-600-31 1/2 Brick 440-700Vin 400-750Vtrans 31Vout 32A 1000W 95%

Rugged, high efficiency Next generation DC-DC bus convertersThese military-grade bus converters are the next-generation, board-mountable, isolated, fixed switching frequency DC-DC converters that uses synchronous rectification to achieve extremely high conversion efficiency. The power dissipated by the converter is so low that a heatsink is not required, which saves cost, weight, height, and application effort. MCOTS-Bus converters are ideal for creating the mid-bus voltage required to drive point-of-load (non-isolated) converters in IBA.

Mil-COTS

95% Efficiency

full Bric

k

4.69”(119.13)

2.48” (63)

0.51”(13)

half Brick

2.3

9” (6

0.6)

2.49

” (6

3)

0.5

1” (

13)

Sixteenth Brick

1.4

4” (

36.5

)

1.04

”(2

6.3)

0.5

”(1

2.7)

Quarter Brick

2.3

9” (6

0.6)

1.5

4”(3

9.01

)

0.5

”(1

2.7)

flanged Quarter Brick

Screening Process Description S-Grade M-Grade

Baseplate Operating Temperature -55°C to +100°C -55°C to +100°C

Storage Temperature -65°C to +135°C -65°C to +135°C

Pre-Cap Inspection IPC-610 Class III • •

Temperature Cycling Method 1010, Condition B, 10 Cycles N/A •

Burn-In 100°C Baseplate 12 hours 96 hours

Final Electrical Test 100% 25°C -55°C, +25°C, +100°C

Final Visual Inspection MIL-STD-2008 • •

Qualification Test Name

Details# Tested

(# Failed)Consistent with

MIL-STD-883F MethodConsistent with

MIL-STD-883F Method 5005

Life Testing Visual, mechanical and electrical test before, during and after 1000 hour burn-in @ full load

15 (0) Method 1005.8 —

Shock- Vibration

Visual, mechanical and electrical test before, during and after shock and vibration tests

5(0) — MIL-STD 202,

Methods 201A and 213B

Humidity +85°C, 85%RH, 1000 hours, 2 minutes on 6 hours off 8 (0) Method 1004.7 —

Temperature Cycling

500 cycles of -40°C to +100°C (30 minute dwell at each temperature)

10(0) Method 1010.8 Condition A

Solderability 15 pins 15 (0) Method 2003 —

DMT -65°C to +110°C across full line, and load specifications in 5°C steps

7(0) — —

Altitude 70,000 feet (21 km) 2(0) — —

Mil-COTS Screening & Qualification

Mil-COTS EMI Filters (Quarter Brick and Half Brick Size)

The EMI filters are available in 28V, 48V and 270V versions. With very low dc resistance, these “off-the-shelf” products will meet your Mil-cOTS needs. These filters provide differential and common-mode attenuation, along with all ceramic stabilizing bulk capacitors and damping resistors.

NegativeInput

Negative Output

Positive Input

Positive Output

PIN 1

PIN 3

PIN 6

PIN 4

RDAMPING

CBULK

PIN 5

PIN 2

Common Mode OutputCommon Mode Input

CIRCUIT SCHEMATIC

OPERATIONAL

• Low DC resistance • Differential-Mode Noise Attenuation models >80dB @ 500kHz and >80dB @ 250kHz

• Common-mode Noise Attenuation models >50dB @ 500kHz and >36dB @ 250kHz

• Bulk capacitance provides input system stabilization for downstream power converters

• No electrolytic capacitors (all ceramic design) • High-voltage isolation between chassis and input / output

• Wide temperature range operation

PRODUCT OPTIONS

• Input voltage ranges match available SynQor DC-DC converters

MECHANICAL

• Industry standard form factors Quarter Brick: 1.54” x 2.39” Half Brick: 2.39” x 2.49”

IN-LINE MANUFACTURING PROCESS

• AS9100 and ISO 9001:2008 certified facility • Full component traceability • Environmental screening options available

DESIGN PROCESS

• Designed to operate with SynQor DC-DC converters to create systems compliant with industry standards. See product datasheets for details.

• Conservative derating guidelines used for reliable operation. See product datasheets for details.

SAFETY

• IEC 60950-1 2nd Edition

EMI DC Filter Modules for Mil-COTS DC-DC convertersSynQor provides EMI filters for the MIL-COTS DC-DC converters. All EMI filters provide >80dB differential mode attenuation and >36dB or >50dB common mode attenuation (model dependent) and include stabilizing bulk capacitors and damping resistors.

PRODUCT FEATURES

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Mil-COTS EMI DC Filters

Model NumberInput Voltage

OutputCurrent

Isolation Voltage (to case)

MaximumDC Resistance @

100°C

Differential-Mode Attenuation

Common-Mode AttenuationContinuous Surge3

(<100ms)

HALF BRICK

MCOTS-F-28-T-HT ±40V +210V, -50V 30A 2250V 50mΩ >80dB @ 250kHz >36dB @ 250kHz

MCOTS-F-270-P-HT ±500V ±630V 9.0A 2250V 80mΩ >80dB @ 250kHz >36dB @ 250kHz

QUARTER BRICK

MCOTS-F-28-P-QT ±40V ±50V 30A 2250V 20mΩ >80dB @ 250kHz >36dB @ 250kHz

MCOTS-F-48-P-QT ±80V ±100V 20A 2250V 32mΩ >80dB @ 250kHz >36dB @ 250kHz

MCOTS-F-270-P-QT ±500V ±630V 4.0A 2500V 180mΩ >80dB @ 500kHz >50dB @ 500kHz

HIGH VOLTAGE Non-Isolated DC-DC Converters

PRODUCT FEATURES

Military-Grade High Voltage, Non-isolated DC-DC convertersThe high input voltage non-isolated DC-DC converters offers unique solutions for converting high-powered, variable voltages to a wide range of output voltages. The converter is a non-isolated buck-boost regulator, which employs synchronous rectification to achieve extremely high conversion efficiency. These products are suitable for use in IBA, or to provide a regulated output voltage from a variable voltage source such as a battery. They can be configured to ‘buck’ the input voltage down or ‘boost’ the input voltage up using a single external resistor.

Mil-COTS Non-Isolated DC-DC ConvertersModel Number Package

SizeInput

VoltageOutput Voltage

Max Output Power

High Efficiency

MCOTS-N-28V-60 1/2 Brick 9-60Vin 0-60Vout 1600W 95% Efficiency

MCOTS-N-28VE-90 1/2 Brick 9-90Vin 0-90Vout 1600W 95% Efficiency

OPERATIONAL

• Ultra-high efficiency up to 95% • Wide input voltage ranges:

9-60V (28V); 9-90V (28VE) • Buck/Boost Mode available • Maximum input/output currents up to 40A • Suitable for use in Intermediate Bus Architectures • On-board input and output filtering • No minimum load requirement • Remote sense and wide output voltage trim

SAFETY

• IEC 60950-1 2nd Edition

MECHANICAL

• Industry standard pin-out configurations • Industry standard footprints:Half Brick: 2.49" x 2.39"

IN-LINE MANUFACTURING PROCESS

• AS9100 and ISO 9001:2008 certified facility • Full component traceability • Environmental screening options available

PROTECTION/CONTROL

• Input under-voltage lockout (UVLO) • Output current limit (OCP) and short circuit protection • Output over-voltage protection (OVP) • Thermal shutdown (OTP) • Output voltage trim

BATTERY CHARGING (Key feature of Trimmable Current Limit)

• Provides the power conversion platform for battery charging • Output current limit is externally controlled for constant-current charging

• Current can be set with an external resistor or an active circuit

• Current analog signal provided for instrumentation and control functions

• Ideal diode output stage with zero back-drive currents prevents discharge of battery when not charging

• Output voltage set-point is independently controlled through trim pin

• Unit will smoothly transition between current and voltage modes as charging cycle needs charge

SynQor Headquarters155 Swanson Road Boxborough, MA 01719-1316Phone: 978-849-0600 Fax: 978-849-0602Toll Free (USA): 888-567-9596E-mail: mqnbofae@synqor.comwww.SynQor.com 005-0005601 - 05/24/2013

SynQor holds the following U.S. patents, one or more of which apply to each product listed in this document. Additional patent applications may be pending or filed in the future. 5,999,417 6,222,742 6,545,890 6,577,109 6,594,159 6,731,520 6,894,468 6,896,526 6,927,987 7,050,309 7,072,190 7,085,146 7,119,524 7,269,034 7,272,021 7,272,023 7,558,083 7,564,702 7,765,687 7,787,261 8,023,290 8,149,597

Advancing The Power Curve®

Headquartered in Boxborough, Massachusetts, at the location of its manufacturing operations, SynQor is a privately owned U.S. ISO 9001 company. SynQor’s converters feature a patented two-stage power topology that greatly improves efficiency and optimizes the power dissipated by the converter. SynQor’s rugged DC-DC converters, AC-DC converters, filters and systems are designed for a wide range of industrial and military applications including those required to withstand harsh environments: railway and transportation systems, industrial motion control, information displays, factory automation, critical military and power generation systems. The Military series of Uninterruptible Power Supply units (UPS), Hi-Rel and Mil-COTS DC-DC converters and EMI filters brings SynQor’s field proven high-efficiency synchronous-rectifier technology to the Military/Aerospace industry. With a design center in Dallas, Texas, and sales/marketing offices throughout the World, SynQor quickly became the technology, quality and service leader for high efficiency DC-DC converters.

Made in USA

Visit our website for more information